Yesterday I started a new baffle, hopefully it will come out good but I am anxious due to the mishaps which very quickly can ruin hours of work
Only had time to do the top 4 driver positions (1 carve with 3 tool operations)
On the machine bed I have attached a gude plate (second surface with rails) that ensure the MDF-stock stay parallell to the Y-axis of the machine.
Pilot and guide holes ensure I can do partial segments with equal spacing, simply lifting the stock-MDF up, slide to the right and align it with the guide hole. Clamp down and machine next segment. Like mentioned before one baffle consist of 6 segments, one top, 4 repeats of middle and one bottom.
1 down, 5 to go…!
(and repeat for 2nd baffle…if all goes well)
- First operation, doing the pilot and guide hole with 6mm flat tool. CC spacing is 4x84mm (20s)
- Second operation, machining the driver openings and mounting flange with 6mm flat tool (10min)
- Third operation, contouring the waveguide surface with 6mm ball tool (20min)
I could do finer contouring but that = more machine time. Earlier tests show that the visible contouring lines quickly dissapear with light sanding in preparation of finishing. I will seal the MDF with epoxy resin which will serve as the primer/base coat.